Method for controlling an electric drive machine

ABSTRACT

A method is provided for controlling an electric drive work machine including an engine and an electric motor that provides power to enable the work machine to travel across a surface terrain at certain ground speeds. In one embodiment, the method may include detecting a reverse directional shift of the work machine causing the work machine to travel in a reverse direction. Further, the method may include performing an engine speed reduction process that reduces a current speed of the engine based on the detected reverse directional shift without reducing a ground speed of the work machine while traveling in the reverse direction.

TECHNICAL FIELD

This invention relates generally to electric drive machines and moreparticularly, to systems and methods for controlling the engine speed ofan electric drive work machine.

BACKGROUND

The increase in fossil fuel consumption coupled with the diminishingsupply of these resources have given rise to the implementation ofelectric drive machines. These machines may be designed to providecombinations of electric and/or internal combustion power to themachines' drive train to reduce fuel consumption. In someconfigurations, an engine powers a generator, which provides electricpower to a battery system and an electric motor. Typically, the electricmotor is configured to drive the wheels or travel mechanisms of the workmachine (e.g., sprockets on a track type tractor, etc.). Other types ofelectric drive machines allow both an engine and electric motor toprovide power to the travel mechanisms of the work machine.

The evolution of electric drive machines have also given rise to newtypes of systems for controlling the power produced by the electricmotor and/or engine. Typically, conventional control systems forelectric drive machines use various machine operating conditions andparameters to adjust the operations of the machine's engine and/orelectric motor in an attempt to increase the performance efficiency ofthe work machine.

Although conventional systems may control an engine in an electric drivemachine, such control is based on anticipated changes to the work loadsexperienced by the vehicle. Accordingly, these systems may requireextensive processing capabilities to determine the appropriateadjustments to be made to the operation of the engine to offset theloads experienced by the machine's motor. Such processing is sometimesnot feasible in working environments where a work machine performsrepeated motions that require many directional shifts and speedfluctuations. To reduce losses experienced by a work machine in suchconditions, some control systems have been developed that take intoaccount machine speed or directional fluctuations. One such system isdescribed in U.S. Pat. No. 5,725,064 (“the '064 patent”), which uses acontrol system to cut off the fuel supply of an electric drive machine'sengine when the machine is in reverse, when an auxiliary component isrunning during idle conditions, or when the motor is exclusively used todrive the machine. The control system in the '064 patent decompressesthe engine following its shut down to reduce engine pumping losses. Thisreduces drag on the motor that may result from the shut down of theengine.

Although the system described in the '064 patent uses a control systemto increase the efficiency of an electric drive machine, it does so in amanner requiring the engine to be shut down. Thus, the vehicle relies onthe electric motor for mobility while in reverse. Further, the '064patent, as well as other conventional electric drive control systems, donot consider overspeed limit conditions during directional shifts.Accordingly, there is a need for an electric drive control system thatcontrols an engine based on directional shifts without complexprocessing or drastic mechanical changes in order to increase fuelefficiency and overspeed limit capabilities during certain directionalshift conditions.

Methods, systems, and articles of manufacture consistent with thedisclosed embodiments are directed to solving one or more of theproblems set forth above.

SUMMARY

A method is provided for controlling an electric drive work machineincluding an engine and an electric motor that provides power to enablethe work machine to travel across a surface terrain at certain groundspeeds. In one embodiment, the method may include detecting a reversedirectional shift of the work machine causing the work machine to travelin a reverse direction. Further, the method may include performing anengine speed reduction process that reduces a current speed of theengine based on the detected reverse directional shift without reducinga ground speed of the work machine while traveling in the reversedirection.

In another embodiment, a system is provided for controlling an electricdrive work machine. The system may include an engine, an electric motorthat provides power to a travel mechanism that allows the work machineto travel across a terrain surface at certain ground speeds and anengine control system. The engine control system may be configured todetermine when the work machine experiences a reverse directional shiftcausing the work machine to operate in a reverse direction. Based on thedetected directional shift the engine control system may send an enginecontrol signal to the engine that reduces the speed of the engine from acurrent engine speed to an adjusted engine speed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A illustrates a block diagram of an exemplary work machineconsistent with certain disclosed embodiments;

FIG. 1B illustrates a block diagram of an exemplary system that may beconfigured to perform certain functions consistent with disclosedembodiments;

FIG. 2 illustrates a block diagram of an exemplary control systemconsistent with certain disclosed embodiments;

FIG. 3 illustrates a flowchart of an exemplary reverse control processconsistent with certain disclosed embodiments; and

FIG. 4 illustrates a flowchart of another exemplary reverse controlprocess consistent with certain disclosed embodiments.

DETAILED DESCRIPTION

Reference will now be made in detail to certain embodiments, which areillustrated in the accompanying drawings. Wherever possible, the samereference numbers will be used throughout the drawings to refer to thesame or like parts.

FIG. 1A illustrates an exemplary work machine 100, shown as a track typework machine, equipped with work implements 102 and capable ofperforming various production operations, such as ripping, grading, andmoving material. Work machine 100 may include an operator's cab 104wherein an operator is positioned to operate work machine 100. Althoughwork implements 102 are shown as being a ripper 106 and dozing blade108, it should be understood that any type of work implements (e.g.,dozer blades, buckets, forks, etc.) or none at all may be implementedand used by work machine 100. Work machine 100 may also include travelmechanisms, such as tracks 103, that engage the ground and is capable ofoperating in forward and reverse on level or sloped terrains.

Further, although work machine 100 is shown as a track type tractormachine, machine 100 may be any type mobile machine that performs atleast one operation associated with a particular industry, such asmining, construction, farming, etc. and operates between or within workenvironments (e.g., construction site, mine site, power plant, etc.).Work machine 100 may also be a mobile machine for use in non-industrialsettings (e.g., machines for personal use). For example, work machine100 may represent a commercial machine, such as a truck, a crane, earthmoving vehicle, a mining vehicle, a backhoe, material handlingequipment, farming equipment, and other types of machines that operatein a commercial or industrial environment. In one embodiment, workmachine 100 is an electric drive work machine that includes an electricmotor that provides at least some power to a drive train of work machine100.

Also, in accordance with certain embodiments, work machine 100 may be amachine that performs tasks that require repeated transitions from aforward and reverse direction while performing these tasks. For example,work machine 100 is depicted as a track type machine that may be used byan operator to manipulate material or terrain using work implements 102by continuously moving machine 100 forward and backward during thecourse of the manipulations.

FIG. 1B illustrates a block diagram of certain components of workmachine 100 that may be configured to perform certain functionsconsistent with certain embodiments. As shown, work machine 100 mayinclude at least an on-board data link 105, a work machine controlsystem 110, an engine control system 120, an engine 130, a generatorsystem 140, an electric motor 150, travel mechanism 155, and one or moresensors 160 and 162.

On-board data link 105 represents one or more proprietary and/ornon-proprietary data links that interconnect modules included in workmachine 100. In one embodiment, data link 105 may represent Society ofAutomotive Engineers (SAE) J1939, Controller Area Network (CAN), etc.standard data links.

Control system 110 represents one or more systems, devices, and/ormechanisms configured to perform certain control functions for workmachine 100 and/or components of work machine 100. Control system 110may be implemented by one or more hardware, software, and or firmwarecomponents. In certain embodiments, control system 110 may be an EngineControl Unit (ECU) embedded in work machine 100, although other forms ofcontrol modules may be implemented. Control system 110 may receivesensor signals from one or more sensors within work machine 100 andproduce commands for controlling one or more other elements of workmachine 100, including other control systems.

Engine control system 120 represents one or more systems, devices,and/or mechanisms configured to perform certain control functions forwork machine 100 and/or components of work machine 100, such as engine130. Control system 120 may be implemented by one or more hardware,software, and or firmware components. In certain embodiments, controlsystem 120 may be an ECU embedded in work machine 100, although otherforms of control modules may be implemented. Control system 120 mayreceive signals and commands from control system 110. Based on thesesignals and commands, control system 120 may generate one or moresignals for controlling the operations of engine 130.

Engine 130 represents an engine that provides power for work machine 100and its components. Engine 130 may be a diesel engine (although othertypes of engines are contemplated) that generates and transfers power toother components of work machine 100 through a power transfer mechanism,such as a shaft.

Electric motor 150 represents a motor that transfers the electric powerreceived from generator 140 into power that drives one or more groundtravel mechanisms 155. Collectively, generator 140 and electric motor150 may represent a drive train system 152 for work machine 100,although additional components (not shown) may be included in thissystem.

Ground travel mechanism 155 may represent one or more types ofmechanical components that allow work machine 100 to travel on thesurface of a type of terrain (i.e., earth surface terrain, subterraneansurfaces, underwater surfaces, etc.). Such components may includewheels, axles, tracks, sprockets associated with tracks, etc. As workmachine 100 travels on a terrain surface, one or more sensors 160 maymeasure, collect, and send speed signals to control system 110reflective of the speed of the machine. Sensor 160 may send speedsignals to control system 110 in response to a request from system 110,or sensor 160 may be configured to send the speed signals periodicallyor in response to a machine event, such as increase in speed, adeceleration event, etc. Further, work machine 100 may change directionswhile traveling. Sensor 162 may be a device that senses directionalshifts of work machine 100 through various components, such as engine130, a transmission system (not shown), travel mechanism 155, etc.Sensor 162 may be configured to send one or more directional shiftsignals to control system 110 directly or indirectly. Alternatively, oradditionally, sensor 162 may send directional shift signals to enginecontrol system 120 for subsequent processing.

Additionally, or alternatively, work machine 100 may sense directionalshifts based on operator inputs associated with the direction of workmachine 100. For example, if the operator changes the direction ofmachine 100 through operator inputs (e.g., forward or reversedirectional mechanisms in the cab of machine 100), one or more signalsindicative of this directional shift may be provided to control system110 or a control system associated with drive train system 152. Further,work machine 100 may include a sensor that monitors the position ofcomponents within motor 150 that reflect the direction of work machine100. The motor sensor may send these signals to control system 110 or acontrol system associated with drive train system 152 for determiningthe direction of work machine 100.

In another embodiment, sensor 162 may also include a sensor device thatmonitors and collects engine speed information from engine 130. Sensor162 may send this information in the form of an engine speed signal tocontrol system 110 and/or engine control system 120 for processingconsistent with certain disclosed embodiments. Further, work machine 100may include sensors that measure the rotational speed of an axle used intravel mechanism 155 that is proportional to the ground speed of machine100 or similar sensors capable of measuring actual ground speed of workmachine 100 through other components of work machine 100.

In certain embodiments, control system 110 sends one or more commands toone or more components of work machine 100 for controlling theiroperations. For example, control system 110 may send a command tocontrol system 120 in response to signals sent or collected from sensors160 and/or 162.

Engine control system 120 may be configured to perform standard enginecontrol unit functions for work machine 100. Additionally, enginecontrol system 120 may be configured to initiate and perform one or moreengine control processes consistent with certain embodiments. FIG. 2shows an exemplary engine control system 120 according to theseembodiments. As shown, engine control system 120 may include aprocessing unit 212, a memory device 214, a sensor interface 216, and acontrol signal interface 218.

Processing unit 212 may represent one or more logic and/or processingcomponents used by control system 120 to perform certain communications,control, and health test functionalities. For example, processor unit212 may be configured for routing information among devices withinand/or external to control system 120. Further, processing unit 212 maybe configured to execute executing instructions from a storage device,such as memory 214. Although FIG. 2 illustrates a single processor unit,control system 120 may include a plurality of processor units, such asone or more general purpose processing units and/or special purposeprocessor units (e.g., ASICS). Processing unit 212 may also include, forexample, one or more of the following: a co-processor, memory,registers, and other processing devices and systems as appropriate.

In certain embodiments, the functionality of processing unit 212 may beembodied within an integrated microprocessor or microcontroller. Such amicrocontroller may, for example, include an integrated CPU, memory, andone or more peripherals. Depending on the implementation, engine controlsystem 120 may include one or more microcontrollers in addition to or inplace of processing unit 212 and memory 214, such as the Microchip'sPIC, the 8051, Intel's 80196, and Motorola's 68HCxx seriesmicrocontrollers.

Memory 214 may represent one or more systems and/or mechanisms capableof storing information. Memory 214 may be embodied with a variety ofcomponents and/or subsystems, including a RAM (random access memory), aROM (read-only memory), magnetic and optical storage elements, organicstorage elements, audio disks, and video disks. In certain embodiments,memory 214 may include one or more programmable, erasable and/orre-useable storage components, such as EPROM (erasable programmableread-only memory) and EEPROM (erasable programmable read-only memory).Memory 214 may also include constantly-powered nonvolatile memoryoperable to be erased and programmed in blocks, such as flash memory(i.e., flash RAM). Memory 214 may provide a primary memory for processor212, such as for storing program code. For example, memory 214 mayinclude program code for communications, kernel and device drivers,configuration information, and other applications that might be embeddedwithin control system 120. Although a single memory is shown, any numberof memory devices may be included in control system 120, and each may beconfigured for performing distinct functions. In one embodiment, memory214 may include program code that, when executed by processing unit 212,performs one or more engine control processes consistent with certainembodiments.

Sensor interface 216 may be an optional device that is configured toreceive one or more sensor signals from one or more respective sensordevices (e.g., sensors 160, 162) that are associated with one or morecorresponding components of work machine 100. In one embodiment, enginecontrol system 120 extracts the signals received at sensor interface 216and provides them to processing unit 212 and/or memory 214 forsubsequent processing. Alternatively, engine control system 120 mayreceive sensor signals over a data link (e.g., data link 105) and datalink interface 218.

Data link interface 218 may represent one or more interface devices thatinterconnect one or more data links (e.g., data link 105) with enginecontrol system 120. Data link interface 218 may connect to proprietaryand non-proprietary data links. In one embodiment, data link interface218 may include virtual (i.e., software-based) ports that allow a singleconnection to act as if there were multiple connections.

Methods and system consistent with certain disclosed embodiments enableengine control system 120 to perform work machine control operations andprocesses. In one embodiment, work machine 100 may perform one or moreprocesses that increase the performance efficiency of work machine 1100through direct or indirect affects to one or more of the machine'scomponents, such as engine 130, motor 150, etc. For example, workmachine 100 may adjust operations of engine 130 and/or other components,while traveling in certain directions, such as reverse.

During operation, work machine 100 may perform work related duties(e.g., traveling, hauling, moving earth, etc.) at various ground speeds,engine speeds, directions, etc. while manipulating various types ofloads. In some instances, work machine 100 may perform cyclical workoperations. For example, work machine 100 may repeatedly changedirections and engine speeds while moving or hauling some type of load,such as when a track type tractor machine moves forward pushing a load(e.g., earth), backs up while experiencing little or no external loads,and moves forward again to push the load. This cyclical process may berepeated all day, or in some instances, all day and night, depending onthe type of work performed by work machine 100 and/or the type of workenvironment work machine 100 may be operating. In one embodiment, workmachine 100 may be configured to perform one or more control processesthat take into account the directional shift, load, and/or engine speedchanges work machine 100 may experience while performing such workrelated duties.

FIG. 3 illustrates a flowchart of an exemplary reverse control processthat may be performed by engine control system 120 and/or other elementsof work machine 100. As mentioned above, work machine 100 may changedirections many times while performing one or more tasks. Accordingly,in one embodiment, engine control system 120, control system 110, orother control systems (e.g., a control system associated with drivetrain system 152) may be configured to detect when work machine 100experiences a directional shift to reverse (Step 310). To detect such achange, control system 110 may receive a directional shift signal fromsensor 162 indicating that work machine 100 has shifted to a reversedirection or mode of operation causing a direction shift to a reversedirection. Sensor 162 may generate the directional shift signal based oninformation collected from travel mechanisms 155, such as the rotationof a sprocket changing direction, based on information collected from atransmission system (not shown), or based on user interface componentsthat provides a signal reflecting that an operator has shifted thedirection of work machine 100 to a reverse direction. The above examplesare not intended to be limiting and other methods of detecting when workmachine 100 has experienced a reverse directional shift may beimplemented.

Once control system 110 receives the directional shift signal fromsensor 162, it may generate and send a message to engine control system120 over data link 105. The message may include information reflectingthe directional shift. Alternatively, sensor 162 may send thedirectional shift signal to engine control system 120 directly (viasensor interface 216) or indirectly through data link 105 and data linkinterface 218. Once received, engine control system 120 may execute areverse control program stored in memory 214. In one embodiment, thereverse control program may perform a process that determines whetherengine control system 120 is configured in a speed parameter mode (Step320). The speed parameter mode may be a mode of operation that allowsengine control system 120 to make adjustments to the operations ofengine 130 based on the speed of work machine 100 (e.g., mph) and/or thespeed of engine 130 (e.g., RPM). If engine control system 120 is notconfigured in a speed parameter mode (Step 320; NO), the reverse controlprocess continues at Step 370, described below. On the other hand, ifengine control system 120 is configured in a speed parameter mode (Step320; YES), system 120 may determine whether the ground speed of workmachine 100 is above a predetermined threshold value while traveling inthe reverse direction (Step 330).

In one embodiment, engine control system 120 may determine the groundspeed of work machine through sensor, 160. For example, as work machinetravels across a terrain surface, sensor 160 may collect ground speedinformation from travel mechanism 155 indicating the ground speed.Sensor 160 may send this information to control system 110 forforwarding to engine control system 120 in the form of a messagedelivered over data link 105. Alternatively, sensor 160 may send a speedsignal to engine control system 120 through sensor interface 216 orindirectly through data link interface 218. Work machine 100 mayimplement different techniques and components for determining groundspeed. For example, in one embodiment, engine control system 120 (orcontrol system 110) may be configured to request the speed sensor datafrom sensor 160 when it detects a directional shift, as performed inStep 310. Alternatively, ground speed may be determined through sensorsthat provide signals associated with the rotational speed of the torqueconverter system output shaft connected to drive train system 152.

Once the ground speed of work machine 100 is determined, engine controlsystem 120 may compare this speed to a predetermined ground speedthreshold value that is programmed in memory 214. The ground speedthreshold value may be a value determined by a user, a computer executedprogram, or a combination of user and computer executed processes.Further, the ground speed threshold value may be based on one or morespecifications associated with one or more components of work machine100.

In one embodiment, the operator of work machine 100, or another user,may select a maximum or desired reverse ground speed prior to, or while,performing some task with machine 100. The operator or user may use auser interface component within machine 100 for selecting the desiredground speed value. The interface component may be analog ordigitally-based and provides a mechanism for the user or operator toselect and change a maximum reverse ground speed value for work machine100. Once the maximum ground speed value is selected, work machine 100may execute a computer process to determine the ground speed thresholdvalue based on the value selected by the operator or user. In oneembodiment, work machine 100 may determine the ground speed thresholdvalue based on a percentage of the maximum ground speed value selectedby the operator or user. Thus, if the maximum ground speed is selectedas 7 mph, work machine 100 may determine the ground speed thresholdvalue as a percentage of the 7 mph value, such as 80% or 5.6 mph.

The above ground speed values are exemplary only and not, intended to belimiting. Work machine 100 may allow the maximum ground speed valueand/or the percentage value used to determine the ground speed thresholdvalue to be many different values. Further, disclosed embodiments mayallow the ground speed threshold value to be determined based on otherinput values or signals. For instance, a user or operator may manuallyselect the ground speed threshold value using an interface device withinwork machine 100. Further, the ground speed threshold value may bedetermined based on other types of values, such as engine speed valuesin RPM. Thus, a user or computer process may select a maximum enginespeed using an interface device in work machine 100, and the groundspeed threshold value may be determined based from the selected maximumengine speed value.

Returning to Step 330, if work machine 100 determines that the groundspeed of work machine 100 does not exceed the threshold value (Step 330;NO), engine control system 120 may determine whether work machine 100has experienced a directional shift to a forward direction (Step 340).Work machine 100 may employ various techniques and components fordetermining when a directional shift has occurred, such as thosedescribe above in connection with Step 310. For example, signalsindicative of operator input related to a manual change from a forwardto reverse (or reverse to forward) direction may be provided to enginecontrol system 120 or control system 110 to determine directionalshifts. Alternatively, sensor signals from various components, such asmotor 150 travel mechanism 155, etc., may reflect directional shifts.Control systems 120 or 110 may receive these sensor signals to detectthe change in directional movement of machine 100.

If no forward directional shift is detected (Step 340; NO), the reversecontrol process continues at Step 320. If, however, a directional shiftto a forward direction is detected (Step 340; YES), the reverse controlprocess ends.

Alternatively, in place of or in addition to detecting directionalshifts, the reverse control process may be terminated in Step 340 basedon a certain ground speed value or a range of ground speed values ofwork machine 100. For example, as work machine 100 decelerates whiletraveling in reverse, a control system (e.g., system 110, 120, or asystem associated with drive train system 152) may determine whether theground speed of machine 100 has reached a certain value or is within acertain range of values. Based on this determination, work machine 100may terminate the reverse control process. For instance, should workmachine 100 reduce its ground speed while traveling in reverse below acertain value or within a range of values (e.g., 0.25 or 0 mph, orbetween 0.25 and 0 mph), machine 100 may determine that the machine maybe approaching a directional shift condition, and thus terminates thereverse control process in anticipation of a directional shift to aforward direction. Additional or other methods of detecting directionalshifts or determining conditions for terminating the reverse controlprocess may be implemented by work machine 100.

Referring back to Step 330, if engine control system 120 determines thatthe ground speed of work machine 100 has exceeded the threshold value(Step 330; YES), system 120 may determine whether work machine 100 isexperiencing a load while traveling in the reverse direction (Step 350).An experienced load may be associated with changes in external orinternal conditions due to operations of work machine 100. For example,a load be experienced based on a change in gradient slope that workmachine 100 may be traveling, such as a hill. Alternatively, oradditionally, work machine 100 may experience a load by performing acertain task using one or more work elements 102 while traveling in areverse direction, such as pushing, pulling, and carrying a load (e.g.,earth, materials, etc.) using work elements 102. This is distinguishedfrom a condition where work machine 100 is backing up on a levelterrain, or without performing some type of extraneous work, such ashauling, dragging, pulling, etc. Based on these conditions, certaincomponents of work machine 100 may perform operations that result inmachine 100 experiencing a change in load. For instance, work machine100 may experience steering loads from steering pumps, drawbar loads,and any other type of load that may take place as a result in terrainchanges, modifications in the type of operations work machine 100performs while traveling in reverse, and/or operations of one or morecomponents within machine 100.

In certain embodiments, work machine 100 may detect a load using one ormore sensors (not shown) that detect changes in slope of terrain, weightof work machine 100, angles of work components, such as a work element102, and even increases in engine speed due to the work being performed.For instance, work machine 100 may be configured to detect when thespeed of engine 130 drops or exceeds a predetermined value in RPM. Basedon these detected changes in speed, work machine 100 may determine thatmachine 100 is experiencing a load. Alternatively, or additionally, workmachine 100 may detect a load when the amount of fuel provided by thefuel supply system to engine 130 increases past a predetermined value orwithin a range of values. Other methods and systems may be implementedby work machine 100 to determine when a load occurs and the aboveexamples are not intended to be limiting.

Returning to Step 350, if engine control system 120 determines that workmachine 100 is not experiencing a load while backing up (Step 350; NO),the reverse control process continues at Step 370, described below. Onthe other hand, if a load is detected (Step 350; YES), engine controlsystem 120 may be configured to disable the reverse control process toallow work machine 100 to deliver as much power (e.g., full power)required to handle the detected load (Step 360). In one embodiment,engine control system 120 may temporarily disable the reverse controlprocess such that it determines whether a directional shift to a forwardtravel direction has occurred (Step 340). If so, the reverse controlprocess ends. If forward directional shift is not detected, the reversecontrol process continues at Step 320.

As explained, if engine control system 120 determines no load isexperienced while traveling in the reverse direction, the speed ofengine 130 may be adjusted in a manner consistent with the disclosedembodiments (Step 370). For example, if engine control system 120determines that the ground speed of work machine 100 is above thethreshold value (e.g., 5 mph), system 120 may generate an engine controlsignal that reduces the speed of engine 130, thus reducing the amount ofpower produced by engine 130. In one embodiment, engine control system120 may execute a program that determines the speed of which engine 130should operate based on one or more parameters associated with workmachine 100. For example, engine control system 120 may adjust the speedof engine 130 based on the current speed of engine 130, the currentpower produced by motor 150, the current ground speed of work machine100, etc. Additionally, or alternatively, engine control system 120 mayaccess a data structure stored in memory 214 (e.g., table, array, map,etc.) that includes data relationships between engine speed and theseone or more other parameters. For instance, engine control system 120may access a table stored in memory 214 that includes a performance mapreflecting a data relationship between engine RPM to ground speeds, anda speed adjustment factor. Thus, for example, if engine 130 is runningat 1950 RPM while work machine 100 is backing up at 6 mph, the map mayindicate that the engine speed should be reduced to 1500 RPM, or by 450RPM. Based on this information, engine control system 120 may generatean engine control signal that causes engine 130 to adjust its speedaccordingly. Other methods and processes may be implemented by workmachine 100 to adjust the operations of engine 130.

In one embodiment, work machine 100 may be configured to disengage oradjust the transfer of power from engine 130 to drive train 152 whileperforming the reverse control process. For example, work machine 100may be configured to allow motor 150 to deliver the same amount,additional, or less, power to travel mechanism 155 when the speed ofengine 130 is adjusted during the reverse control process. This enableswork machine 100 to continue traveling at certain ground speeds (e.g.,constant, increased, etc.) while reducing the speed of engine 130. Suchfeatures reduce the amount of heat loss experienced by work machine 100because of these reduced engine speeds. Further, implementing thedisclosed embodiments allow heat load sharing because higher heat loadfrom motor 150 is mitigated with lower heat load from engine 130.Additionally, because engine 130 is operating at reduced speeds while inreverse, fuel consumption is reduced. Further, noise pollution may bereduced because of the reduced engine speed.

Also, the disclosed embodiments enable work machine 100 to improve itsretarding performance because the reduced engine speed provides agreater potential to the engine overspeed limit during direction shiftconditions. Overspeed limit is a value associated with the structuralintegrity of engine 130 and other components of work machine 100. Incertain embodiments, the overspeed limit represents the maximum (or nearmaximum) engine speed work machine 100 can handle when experiencing adirectional shift. For example, when work machine 100 changes direction,the resulting kinetic energy from decelerating work machine 100 willhave to be absorbed, stored, or dissipated. Thus, the greater thedifference between the engine speed and overspeed, limit, the morekinetic energy engine 130 or other work machine 100 components canabsorb when machine 100 experiences a directional shift to a forwarddirection. To better illustrate this concept, consider the followingexample. Work machine may be rated with an overspeed limit of 2500 RPM.Suppose, for example, that work machine 100 is traveling in a reversedirection while the engine speed is running at 2000 RPM. The differencebetween the overspeed limit (i.e., 2500 RPM) and the current enginespeed (i.e., 2000 RPM) relates to an amount of kinetic energy workmachine 100 or engine 130 can handle when the machine shifts to aforward direction (i.e., 500 RPM). Work machine 100 is able to increasethe amount of kinetic energy by reducing the engine speed below 2000 rpmprior to the directional shift occurring.

FIG. 4 illustrates a flowchart of another exemplary reverse controlprocess that takes overspeed limit into consideration. In thisembodiment, engine control system 120 and/or control system 110 may beconfigured to detect when work machine 100 experiences a directionalshift to reverse in a manner similar to that described in connectionwith Step 310 of FIG. 3 (Step 410). Based on a detected directionalshift, engine control system 120 receives data reflecting the change intraveling direction of work machine 100.

Once such an indication is received, engine control system 120 mayexecute a reverse control program stored in memory 214. In oneembodiment, the reverse control program may perform a process thatdetermines whether engine control system 120 is configured in a speedparameter mode, similar to that described above with respect to Step 320of FIG. 3 (Step 420). If engine control system 120 is not configured ina speed parameter mode (Step 420; NO), the reverse control processcontinues after Step 470, described below. On the other hand, if enginecontrol system 120 is configured in a speed parameter mode (Step 420;YES), system 120 may determine whether the ground speed of work machine100 is above a predetermined threshold value while traveling in thereverse direction in a manner similar to that described in connectionwith Step 330 of FIG. 3 (Step 430).

Once the ground speed of work machine 100 is determined, engine controlsystem 120 may compare this speed to a predetermined ground speedthreshold value that is programmed in memory 214. If the ground speed ofwork machine 100 does not exceed the threshold value (Step 430; NO),engine control system 120 may determine whether work machine 100 hasexperienced a directional shift to a forward direction (Step 440) in amanner similar to that described above in connection with Step 340 ofFIG. 3. If no forward directional shift is detected (Step 440; NO), thereverse control process continues at Step 420. If, however, adirectional shift to a forward direction is detected (Step 440; YES),the reverse control process ends.

Referring back to Step 430, if engine control system 120 determines thatthe ground speed of work machine 100 has exceeded the threshold value(Step 430; YES), system 120 may compare the current engine speed ofengine 130 to an overspeed limit stored in memory 214 (Step 450). If theengine speed does not exceed, or is not within a predetermined range of,the overspeed limit (Step 460; NO), the alternate reverse controlprocess continues at Step 440. On the other hand, if the engine speedexceeds, or is within a predetermined range of, the overspeed limit(Step 460; YES), engine control system 120 may adjust the speed ofengine 130 in a manner similar to that described in connection with Step370 of FIG. 3 (Step 470).

Thus, in certain embodiments, control system 120 may execute a processthat determines the kinetic energy level of work machine 100 based onthe overspeed limit and current engine speed of work machine 100. Usingthe determined kinetic energy, control system 120 may adjust the speedof engine 130 to meet the determined kinetic energy level prior to orduring directional shifts of work machine 100.

INDUSTRIAL APPLICABILITY

In certain embodiments, an electric drive work machine may perform tasksthat directional shifts to take place consistently over an extendedperiod of time. For example, the work machine, such as a dozer or rippertype machine, may perform tasks that require the machine to repeatedlytravel in reverse and forward while manipulating terrain or materials.Methods and systems consistent with the disclosed embodiments allow thework machine to increase its performance during these repeated reversedirectional cycles. In certain embodiments, the work machine mayselectively adjust the speed of its engine when it travels in a reversedirection. The work machine may be configured to use its electric motorto maintain the machine's ground speed while backing up and while theengine speed is reduced, thus increasing fuel economy, improvingretarding performance, and reducing heat loss from the engine. Incertain embodiments, the work machine may selectively disable certainfeatures when the machine experiences loads while traveling in a reversedirection. Further, the work machine may be configured to adjust enginespeeds based on overspeed limits associated with the work machine or itscomponents.

Although the disclosed embodiments have been described with respect toreverse directional shifts, other types of directional shifts may beconsidered and implemented. For example, certain embodiments may beapplied to directional shifts from reverse to a forward direction.

As described, engine control system 120 may be configured to disable thereverse control process when the work machine experiences a load whiletraveling in reverse. An example of such a load is when work machine 100is backing up a sloped terrain surface. In such conditions, work machine100 may be configured to maintain or reduce the ground speed of workmachine through the power produced by motor 150. Further, when enginecontrol system 120 determines that the speed of engine 130 may bereduced, the power provided by motor 150 may also be reduced based onone or more parameters associated with work machine 100 and/or theterrain surface on which the machine is traveling. For example, insituations where the terrain surface sloped downward, engine controlsystem 120 may be configured to adjust the speed of engine 130 to reducethe amount of heat and power wasted when machine 100 backs down thedeclined slope. At the same time, in some embodiments, work machine 100may be configured to reduce the power provided by motor 150 to reduceunnecessary heat losses while traveling in reverse.

The disclosed embodiments may be implemented in various environments andare not limited to work site environments. Other embodiments will beapparent to those skilled in the art from consideration of thespecification and practice of the embodiments disclosed herein.

1-27. (canceled)
 28. A method for controlling an electric drive machineincluding an engine and an electric motor that provides power to enablethe machine to travel across a surface terrain at certain ground speeds,the method comprising: detecting a reverse directional shift of themachine causing the machine to travel in a reverse direction; andperforming an engine speed reduction process that reduces a currentspeed of the engine based on the detected reverse directional shiftwithout reducing a ground speed of the machine while traveling in thereverse direction.
 29. The method of claim 28, wherein the methodfurther includes: determining whether the machine is experiencing a loadwhile traveling in the reverse direction; and disabling the engine speedreduction process when the machine is experiencing a load whiletraveling in the reverse direction.
 30. The method of claim 28, furtherincluding: determining whether the ground speed of the machine exceeds apredetermined threshold speed value; and bypassing the engine speedreduction process when the ground speed of the machine does not exceedthe predetermined threshold speed value.
 31. The method of claim 30,further including: determining whether the machine is experiencing aload while traveling in the reverse direction; and disabling the enginespeed reduction process when the machine is experiencing a load whiletraveling in the reverse direction.
 32. The method of claim 29, whereindetermining whether the machine is experiencing a load while travelingin the reverse direction includes: determining that the machine isbacking up on a sloped terrain surface.
 33. The method of claim 29,wherein determining whether the machine is experiencing a load whiletraveling in the reverse direction includes: determining that themachine is manipulating a load while traveling in the reverse direction,wherein manipulating the load includes at least one of pushing the load,pulling the load, and carrying the load.
 34. The method of claim 28,wherein performing the engine speed reduction process includes:determining an adjusted engine speed based on at least one of thecurrent speed of the engine and the ground speed of the machine; andgenerating a control signal that reduces the current speed of the engineto the adjusted engine speed.
 35. The method of claim 34, whereinperforming the engine speed reduction process further includes: allowingthe motor of the machine to produce sufficient power to at leastmaintain the ground speed of the machine while traveling in the reversedirection.
 36. A method for controlling an electric drive machineincluding an engine and an electric motor that provides power to enablethe machine to travel across a surface terrain at certain ground speeds,the method comprising: detecting a directional shift of the machinecausing the machine to operate in a new directional cycle that isdifferent from a current directional cycle; and performing an enginespeed adjustment process that adjusts a current speed of the enginebased on the detected directional shift without adjusting a ground speedof the machine during the new directional cycle.